Stepped Composite Rework Patch for Volatile Release
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Solution Overview
Problem
Existing methods for reworking damaged composite structures, such as those in aircraft, are time-consuming and risk further damage due to material removal and heat cycles, and can trap volatiles and substances within the repair patch, compromising its integrity and longevity.
Innovation Solution
A rework part configuration featuring a bottom composite layer with a perimeter extending beyond the upper composite layer, bonded to the structure with a bottom adhesive layer, and an upper composite layer bonded to either the bottom or intermediate layers using a rework part adhesive layer, allowing for successive layering without draping and enabling air and substance aspiration without breather holes, using low-temperature adhesives to minimize further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If layers are successively stacked with each layer draping over underlying layers, then a sealed patch structure is formed, but volatiles and air become trapped inside the patch
Solution Approach 1:
The patch is divided into multiple discrete layers (first layer, second layer, third layer) with progressively smaller perimeters. This segmentation allows each layer to be independently positioned and bonded, creating pathways for volatile release while maintaining overall structural integrity.
Solution Approach 2:
The solution transitions from a two-dimensional draped configuration to a three-dimensional stepped configuration where layers are bonded at different elevations. The perimeters of successive layers are positioned at different heights, creating vertical pathways that allow trapped substances to escape while maintaining the sealed structure.
2Object-generated harmful factors
If breather holes are drilled into the patch to release trapped substances, then volatile release is enabled, but structural integrity of the patch is reduced
Solution Approach 1:
Instead of creating discrete holes through the patch, the structure is segmented into multiple layers with progressively smaller perimeters. The interfaces between layers create continuous pathways for volatile release, eliminating the need for breather holes while preserving structural integrity.
Solution Approach 2:
The adhesive layers between successive patch layers serve as intermediaries that both bond the layers together and create pathways for volatile release. The adhesive material allows trapped substances to pass through the layer interfaces without compromising the structural connection between layers.
3Reliability
If material is removed from damaged composite structure, then damaged portion is eliminated, but risk of further damage increases
Solution Approach 1:
The patch layers are pre-configured with progressively smaller perimeters before application. This preliminary configuration ensures that when the patch is bonded to the damaged structure, the layered structure automatically creates pathways for volatile release without requiring additional material removal or drilling operations that could cause further damage.
4Reliability
If bonded rework is used to repair composite structures, then repair is achieved, but time delays and multiple heat cycles are required
Solution Approach 1:
The patch is segmented into multiple layers that can be independently prepared and positioned. This segmentation allows for more efficient application processes and reduces the need for multiple separate bonding operations, thereby reducing overall repair time while maintaining repair effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for efficient and damage-minimizing repair of composite structures by preventing substance trapping and maintaining structural integrity, reducing the risk of further damage and extending the repair's effectiveness and lifespan.
Implementation Method 1
a bottom adhesive layer adhering the bottom composite layer to the composite structure
Implementation Method 2
a rework part adhesive layer bonding the upper composite layer to either the bottom composite layer or to an intermediate composite layer
Data Source
AI summary
A rework part for a composite structure is described. The rework part comprises an upper composite layer comprising an upper perimeter that extends beyond a damaged area of the composite structure, and a bottom composite layer between the composite structure and the upper composite layer, the bottom composite layer comprising a bottom perimeter that extends beyond the upper perimeter of the upper composite layer. The rework part further comprises a bottom adhesive layer adhering the bottom composite layer to the composite structure, and a rework part adhesive layer bonding the upper composite layer to either the bottom composite layer or to an intermediate composite layer.